Appliqué to provide a design on a fabric

ABSTRACT

An appliqué of the invention comprises a disposable carrier film onto which a release layer and PU inks are printed using layering techniques. The ink layers can be multicoloured and each colour is applied sequentially using a conventional screen-printing method. A back-up, a lacquer layer, and an adhesive layer are printed in sequence over the ink layers. The ink includes reflective particles providing the optical effect of a 3-dimensional appliqué. The artwork is created by overlapping design layers to controlled specification sequences. The ink, because of the additives, creates a desired colour tone, and this may be enhanced by layering of the ink in an overlapping region. Thus, there are three main regions, namely a central region with reflective ink, a “shoulder” region with overlapping matt and reflective inks and an outer region with only matt ink.

The present application is a Continuation application of U.S.application Ser. No. 14/605,352, filed Jan. 26, 2015, which is aContinuation application of U.S. application Ser. No. 13/262,581, filedFeb. 23, 2012, now U.S. Pat. No. 8,940,387, which is a National Stage ofPCT/IE2010/000018, filed Apr. 1, 2010, which claims priority fromIreland Application No. 2009/0255, filed Apr. 1, 2009, the entirecontents of each application being incorporated herein by reference intheir entirety.

INTRODUCTION

The invention relates to application of designs to textiles or fabric,for example a garment such as a sports shirt.

In this specification, the term “appliqué” means a decorative patch orbadge, which is applied to a fabric to impart a decorative design suchas a logo on the fabric such as a garment.

The invention is directed towards providing an appliqué having a “3D”effect, with minimum impact on manufacturing complexity.

SUMMARY OF THE INVENTION

According to the invention, there is provided an appliqué for applying adesign to a fabric, the appliqué comprising:

-   -   at least one ink layer printed on a substrate; and    -   an application adhesive suitable for adhering the appliqué to a        fabric,    -   wherein the appliqué is adapted to provide a three-dimensional        visual effect.

In one embodiment, at least one ink layer incorporates an additive toprovide a three-dimensional visual effect in combination with otherparts of the appliqué.

In one embodiment, the additive comprises reflective particles.

In one embodiment, the reflective particles are coated in titaniumdioxide or iron oxide.

In one embodiment, the additive comprises an agent which expands, suchas with application of heat.

In one embodiment, the agent is a blowing agent.

In one embodiment, there are multiple layers of ink at least two ofwhich only partly overlap.

In one embodiment, a layer includes an additive such as reflectiveparticles or blowing agent and at least one other layer does not includean additive.

In one embodiment, the substrate is non-planar.

In one embodiment, the appliqué further comprises an insert of amaterial such as fabric or foil to provide a surface profile.

In one embodiment, the insert bridges stacks of layers including the inkand the substrate.

In one embodiment, the stacks include an upper disposable carrier, arelease adhesive layer, an ink layer, and an opaque backer layer whichis bonded to a lacquer layer.

In one embodiment, the insert is secured to the stack on each side byadhesive in a manner whereby it is free-floating within the appliqué.

In one embodiment, an ink is printed alongside a flock on a substrate ina desired pattern.

In one embodiment, the surfaces of the ink and of the flock are atdifferent levels.

In one embodiment, the flock fibres are reinforced with a permanentthermosetting adhesive layer.

In one embodiment, the appliqué comprises an upper disposable carrierand a release adhesive layer.

In one embodiment, the carrier is of polyester material.

In one embodiment, the ink is between a release adhesive layer and abacker layer.

In one embodiment, at least one ink is a polyurethane ink.

In one embodiment, the backer layer is positioned between an ink layerand a lacquer layer.

In one embodiment, the backer layer comprises a polyurethane-based ink

In one embodiment, the backer layer comprises a single polyurethane inklayer or multiple polyurethane ink layers.

In one embodiment, a lacquer layer is positioned between a backer layerand an adhesive layer.

In one embodiment, the lacquer layer allows the appliqué to stretch whenthe appliqué is applied to a fabric.

In one embodiment, the appliqué comprises an adhesive layer comprising ahotmelt powder.

In one embodiment, the appliqué comprises an adhesive layer comprisingan activated permanent thermosetting compound.

In one embodiment, the appliqué comprises an adhesive layer comprising amigration-resistant blocking agent.

In another aspect, the invention provides a garment or piece of fabriccomprising any appliqué as defined above adhered thereto.

In a further aspect, the invention provides a method of decorating afabric comprising the steps of applying any appliqué as defined above tothe fabric.

In a further aspect, the invention provides a method of manufacturingany appliqué as defined above comprising the steps of depositing the inkon the substrate in a manner to provide a three-dimensional effect.

In one embodiment, the method comprises the step of blending the inkwith an additive to achieve a desired visual effect.

In one embodiment, the additive includes reflective particles.

In one embodiment, the additive includes a blowing agent or any otheragent which expands to increase height of the ink.

In one embodiment, the method comprises the step of overlapping inklayers in a pattern chosen according to a desired three-dimensionalvisual effect.

In one embodiment, the method comprises the step of depositing an ink toa greater depth than another ink on the substrate.

In one embodiment, the inks are deposited with different screen-printingstencils.

In one embodiment, the inks have different viscosities.

In one embodiment, an insert is retained within the appliqué.

In one embodiment, the insert bridges stacks of layers on either side ina manner whereby the insert has the effect of floating.

In one embodiment, at least some of the ink is deposited alongside flockin a desired pattern on the substrate.

DETAILED DESCRIPTION OF THE INVENTION

The invention will be more clearly understood from the followingdescription of some embodiments thereof, given by way of example onlywith reference to the accompanying drawings in which:—

FIG. 1 is a cross-sectional view of an appliqué of the invention forapplication of a design to a garment, FIG. 2 is a cross-sectional viewof the appliqué after application onto textile fabric (F), and FIG. 3 isa plan view of the appliqué;

FIGS. 4 and 5 are cross-sectional views of an appliqué before and afterapplication to a fabric, the appliqué having a PU ink incorporating ablowing agent to give a 3D effect;

FIGS. 6 and 7 are cross-sectional views of an appliqué before and afterapplication to a fabric, the appliqué having PU ink raised in ascreen-printed pattern to provide a 3D effect;

FIGS. 8 and 9 are cross-sectional views of an appliqué before and afterapplication to a fabric, the appliqué having a 3D textile insert; and

FIGS. 10 and 11 are cross-sectional views of an appliqué before andafter application to a fabric, the appliqué having flock alongside PUink on a single substrate to provide a 3D effect.

The invention provides an appliqué which gives a 3D visual effect. Thisis achieved by way of ink layering techniques and/or incorporation ofadditives such as reflective particles in an ink and/or non-planarconfiguration of a substrate and/or incorporation of a textile insert toprovide physically different depths, and/or deposition of ink and flockof different or similar depths alongside each other in a pattern.

Referring to FIGS. 1 to 3, an appliqué 9 of the invention comprises adisposable carrier film 7 onto which a release layer 6 and PU inks 5 and4 are printed using layering techniques. The ink layers 4 and 5 can bemulticoloured and each colour is applied sequentially using aconventional screen-printing method. A back-up 3, a lacquer layer 2, andan adhesive layer 1 are printed in sequence over the ink layers.

The ink 4 includes additives, in this embodiment, reflective particles.These aspects provide the optical effect of a 3-dimensional appliqué.The artwork is created by overlapping design layers to controlledspecification sequences. The ink 4, because of the additives, creates adesired colour tone, and this may be enhanced by layering of the inks asillustrated in the overlapping region 8. Thus, as viewed in FIG. 3,there are three main regions, namely:

-   -   a central region with reflective ink 4,    -   a “shoulder” region with overlapping matt and reflective inks 4        and 5, and    -   an outer region with only matt ink 5.

The ink 4, being blended with light reflecting particles, has a bright,sparkly shimmer, with a degree of light scattering behaviour. The lightscattering ability of the additive is dependent directly on theconcentration of additive blended into the ink. Blends with higheramounts of the additive will scatter more light than those with loweramounts of additive. Polyurethane ink has a low light scatteringability. Therefore the ink 5 has a matt appearance and contrast betweenthe matt ink 5 and the reflective ink 4 intensifies the optical3-dimensional effect.

The adhesive 1 comprises an adhesive system made from adhesive combinedwith hotmelt adhesive powder. The adhesive can include one or more of(but not limited to) acrylic; epoxide; polyamide; polyester, polyolefin;polyurethane; and polyurethane ester adhesives. For example, theadhesive TO485 polyurethane adhesive can be used.

To apply a design to a textile, the appliqué 9 is simply placed on thetextile with the disposable carrier face up 7, with the adhesive layer 1in contact with the textile. Heat and pressure are applied so theadhesive 1 impregnates into the fabric (F) to seal the appliqué inplace.

The invention has the major advantage of optically creating a3-dimensional effect even there is minimal impact on the manufacturingprocess. Also, the appliqué is very simple to apply with heat andpressure, in a conventional manner.

Referring to FIG. 4 and FIG. 5, in another embodiment, an appliqué 10has a physical 3-dimensional effect by printing PU inks 15 alongsideinks 14 blended with additives which give varying heights to appliqué(best illustrated in FIG. 5). The additives in the ink 14 are chemicallyformulated blowing agents, and control of composition proportions allowsexcellent control of the ink thickness. The blowing agents are activatedwith heat upon application to expand from the depth shown in FIG. 4 tothat shown in FIG. 5.

Referring to FIG. 6 and FIG. 7, in another embodiment, an appliqué 20provides a physical 3-dimensional effect by printing inks 24 and 25 ofvarying thicknesses onto a disposable carrier 27. Thus, there is flatpolyurethane ink and raised inks. The invention has the major advantageof incorporating different depth of deposit, which is visuallynoticeable. The raised ink 24 is raised because of the use of thickstencil screen technology and PU ink of a higher viscosity to achievethe greater height. Also, the appliqué is easy to apply to fabric (F)using heat and pressure in a conventional manner. The surface of theappliqué can be textured. Again, the appliqué 20 has a backer layer 23,a lacquer layer 22, and an adhesive dispersion 21.

Referring to FIG. 8 and FIG. 9, in another embodiment, an appliqué 30provides a physical 3-dimensional effect by including in an appliqué alaser or die-cut motif; textile insert 34 between stacks of PU ink 35,backer 33, lacquer 32, and adhesive dispersion 31. The insert is appliedso that the appliqué can be heat-applied in an easy one-step operation.

The insert may alternatively be of foil, flock, natural or syntheticmaterials including textiles, film or hologram for example. The physicalconfiguration is achieved by leaving an open area for the insert to showthrough. The insert is cut smaller than the total design area so thatsome adhesive remains outside the insert area for application.

The adhesive 21 is a hot-melt adhesive comprises a thermoplastic filmmade from aromatic or aliphatic thermoplastic. The hot-melt film caninclude one or more of; (but not limited to) polyamide; polyester;polyolefin; polyurethane; and polyurethane ester. For example, thehot-melt film can be 76 μm Bemis Polyester Hotmelt Film 5214.

Referring to FIGS. 10 and 11, in another embodiment, in an appliqué 40 aphysical 3-dimensional effect is achieved by printing multiple coloursof flat PU inks 45 and multiple flocks 44 onto the same disposablecarrier 47. The PU inks 45 and backer, lacquer, and adhesive layers 43,42 and 41 are printed onto the disposable carrier 47 in the areas wherePU ink is desired. Areas of the design where flock 44 is required areleft void on the carrier during PU ink printing. These areas are thenelectrostatically flocked in the desired pattern and the flock adhesive48 is printed last. The appliqué 40 is easy to apply to fabric (F) usingheat and pressure. The surface of the appliqué has a visible heightdifference between the flat PU ink 45 and the raised flock fibres 44.

This embodiment has the major advantage of creating a combination printwhere richly textured pile gives a plush hand feel alongside the smoothflat surface of polyurethane inks. Thus, the invention makes use ofcombining polymer appliqué technology with flock printing techniques.This combines, for example, the use of lightweight, sports-performancepolyurethane appliqué materials with flock printing technology directlyonto the carrier to create a polyurethane-flock combined appliqué. Theflock can be any electro statically chargeable fibre, such as fibresmade from rayon, nylon, cotton, acrylic and polyester.

The Polyurethane adhesives 1, 11, 21, 31, and 41 referred to above areall of the cross-linking solvent-based polyurethane emulsion type orwater-based polyurethane emulsion type, the particular cross-linking foreach adhesive being chosen to suit the substrate. While alternatives arepossible such as an acrylic-based adhesive for the release adhesive 46(on disposable Polyester film 47), it is believed that polyurethaneemulsions are more effective.

The flock adhesive 48 referred to above is of the cross-linkingwater-based acrylic emulsion type, the particular cross-linking for eachadhesive being chosen to suit the substrate. Alternatives are possiblesuch as a polyurethane-based adhesive.

The following summarizes advantageous features of the invention invarious embodiments to achieve a 3-dimensional effect:

-   -   Artwork layering techniques, ink formulations with additives        such as light reflective particles, printing inks of varying        thicknesses onto a carrier, and/or printing both flock alongside        dink on the same carrier.    -   A combination of a film-backed polyurethane heat transfer with a        laser or die cut motif of fabric or other materials, where both        are combined to allow them to be heat applied in an easy one        step heat application operation. The combination of a PU        appliqué with other materials creates a physical 3-dimensional        effect.    -   The ink incorporates blended mass-reducing particles, and/or        fluorescent particles, and/or phosphorescent particles, and/or        ultra violet particles or inks, and/or thermochromic particles,        and/or photochromic particles, and/or electorchromic particles,        and/or ‘mirror’ particles, and/or porous particles, and/or        metallic particles, and/or solar charged particles, and/or        kinetic charged particles, and/or magnetic particles, and/or        chemical agents which undergo changes to structure and thickness        at defined temperatures    -   Inks of different thicknesses are printed on the same carrier to        achieve different heights.    -   The ink has added colour pigment and/or dyes.    -   The ink may be fully transparent, or translucent, or opaque.    -   The ink may be ultra violet activated, have elastic stretch and        recovery characteristics, be compression resistant, be        malleable, and/or have compression and recovery characteristics.    -   It may incorporate fabric material, which may be sublimated with        a pre-printed pattern, or may be in its natural state.    -   The fabric material may be pre-dyed and or coated. Dyed fabric        can include but not exclusively standard textile dyes but this        can also include metallic coatings, fluorescent coatings/dyes,        heathers and other surface treatment.    -   An insert may be included and this may be a fabric which is a        woven fibre including, plain, twill, crow's feet, basket or        satin weave. These fabrics can be made of        -   Natural Fabrics: linen, silk, satin, denim, canvas, jute,            velvet, cotton, wool, organza, brocades, felt, natural            recycled fabrics, organic fabrics, hemp.        -   Synthetic Fabrics: polycotton, viscose, acetate, polyamide,            organza, chiffon, sateen, lycra, spandex, lurex, taffeta,            velour, polyester, acrylic, nylon, technical/composite            fabrics, or recycled fabrics.    -   The insert may be a flocked appliqué, or a film which can be        coated and uncoated, or a metallic foil or an organometallic        foil which can be coated and uncoated.    -   The insert may be a motif, may have a holographic pattern,        insert includes audio or visual digital components, include RF        Id Tags components.    -   Flock fibres, where included, can be pre dyed. The flock fibre        can be any electro statically chargeable fibre, such as fibres        made from rayon, cotton, nylon, acrylic and polyester. The flock        fibres are of a high lustre type, and/or translucent, and/or of        differing lengths, and/or of a pre-determined length, and/or        contain an Ultra Violet coating    -   Resin, where used, could encapsulate delicate fabrics or other        materials.

An application adhesive may be a polyurethane resin, or a hotmelt, or anacrylic co−

-   -   polymer and a polyurethane resin.

The following are examples of the inks, adhesives and additives, whichcan be used in various embodiments.

Polyurethane Ink 4:

Product: Nylotex NX Series

Chemical Description: Polyurethane ink dispersion

Polyurethane Ink 5:

Product: Nylotex NX Series

Chemical Description: Polyurethane ink dispersion

Polyurethane Ink 14:

Product: Nylotex NX Series

Chemical Description: Polyurethane ink dispersion

Polyurethane Ink 15:

Product: Nylotex NX Series

Chemical Description: Polyurethane ink dispersion

Polyurethane Ink 24:

Product: Nylotex NX Series

Chemical Description: Polyurethane ink dispersion

Polyurethane Ink 25:

Product: Nylotex NX Series

Chemical Description: Polyurethane ink dispersion

Polyurethane Ink 35:

Product: Nylotex NX Series

Chemical Description: Polyurethane ink dispersion

Polyurethane Ink 45:

Product: Nylotex NX Series

Chemical Description: Polyurethane ink dispersion

Backer 3:

Product: Nylotex NX Series

Chemical Description: Polyurethane ink dispersion

Backer 13:

Product: Nylotex NX Series

Chemical Description: Polyurethane ink dispersion

Backer 23:

Product: Nylotex NX Series

Chemical Description: Polyurethane ink dispersion

Backer 33:

Product: Nylotex NX Series

Chemical Description: Polyurethane ink dispersion

Backer 43:

Product: Nylotex NX Series

Chemical Description: Polyurethane ink dispersion

Lacquer 2:

Product TO458

Chemical Description: Polyurethane adhesive dispersion

Lacquer 12:

Product: TO458

Chemical Description: Polyurethane adhesive dispersion

Lacquer 22:

Product: TO458

Chemical Description: Polyurethane adhesive dispersion

Lacquer 32:

Product: TO458

Chemical Description: Polyurethane adhesive dispersion

Lacquer 42:

Product: TO458

Chemical Description: Polyurethane adhesive dispersion

Adhesive 1:

Product: D 1365 & TO458

Chemical Description: Co-polyester hotmelt adhesive powder dispersed ina Polyurethane adhesive dispersion

Adhesive 11:

Product: D 1365 & TO458

Chemical Description: Co-polyester hotmelt adhesive powder dispersed ina Polyurethane adhesive dispersion

Adhesive 21:

Product: D 1365 & TO458

Chemical Description: Co-polyester hotmelt adhesive powder dispersed ina Polyurethane adhesive dispersion

Adhesive 31:

Product: D 1365 & TO458

Chemical Description: Co-polyester hotmelt adhesive powder dispersed ina Polyurethane adhesive dispersion

Adhesive 41:

Product: D 1365 & TO458

Chemical Description: Co-polyester hotmelt adhesive powder dispersed ina Polyurethane adhesive dispersion

Adhesive 48:

Product: TUBTRANS BOND-3,

Chemical Description: Acrylic Co-Polymer in aqueous dispersion

Additive in ink 4:

Product: SIPI558 FM Pearl Glitter Speciality Effect,

Chemical Description: Mica platelets coated with various thicknesses oftitanium dioxide or iron oxide.

Additive in ink 14:

Product: NUPUFF 10250NPF,

Chemical Description: Blowing agent dispersed in PU ink.

Polyurethane Ink Product: Nylotex NX Series

Supplier of above inks:

Fujifilm Sericol Limited

Pysons Road, Broadstairs, Kent. CT10 2LE, England.

Polyurethane Ink Backer Product: Nylotex NX Series

Supplier of above adhesives:

Fujifilm Sericol Limited,

Pysons Road, Broadstairs, Kent. CT10 2LE, England.

Lacquer Product: TO458

Supplier of above adhesives:

Fujifilm Sericol Limited,

Pysons Road, Broadstairs, Kent. CT10 2LE, England.

Adhesive Product: TO458

Supplier of above adhesives:

Fujifilm Sericol Limited,

Pysons Road, Broadstairs, Kent. CT10 2LE, England.

Adhesive Product: Tubitrans Bond 3

Supplier of above adhesives:

CHT R. BEITLICH GMBH,

Werk Oyten, Rudolf-Diesel-StraBe 19-21, D-28876 Oyten, Germany

Hotmelt Product:

Product: ADHESIVE HOTMELT NAME

Chemical Description: EMS-Griltech Griltex® D 1365E Copolyester HotmeltAdhesive

Supplier of above adhesives: EMS-CHEMIE AG

Business Unit EMS-GRILTECH, Reichenauerstrasse, CH-7013 Domat,Switzerland.

Additive to ink 4: Product: SIPI558 FM Pearl Glitter Speciality Effect,Supplier of above additive: Nazdar Ltd., Barton Road Heaton, Mersey,Stockport, England,

SK4 3EG

Additive Product to ink 14: NUPUFF 10250NPF,

Supplier of above additive: Nazdar Ltd., Barton Road Heaton, Mersey,Stockport, England,

SK4 3EG

The invention is not limited to the embodiments described but may bevaried in construction and detail. For example, the appliqué could beapplied to a fabric other than that of a garment.

The invention claimed is:
 1. An apparatus, comprising: a fabric; and aninsignia adhered to the fabric, wherein the insignia provides athree-dimensional visual effect while adhered to the fabric, theinsignia includes at least one ink layer, which provides at least inpart the three-dimensional visual effect, and the insignia includes afirst ink section and a second ink section, the second ink sectionhaving additive particles not present in the first ink section, thefirst and second ink sections provide at least in part thethree-dimensional visual effect.
 2. The apparatus of claim 1, wherein:the insignia includes ink blended with additives that give varyingheights to the insignia.
 3. An apparatus, comprising: a fabric; and aninsignia adhered to the fabric, wherein the insignia provides athree-dimensional visual effect while adhered to the fabric, theinsignia includes at least one ink layer, which provides at least inpart the three-dimensional visual effect, and the insignia includes inkand flock fibres, wherein a visible difference in height exists betweenthe ink and the fibres.
 4. The apparatus of claim 3, wherein: theinsignia includes a PU ink raised in a screen-printed pattern to provideat least in part the three-dimensional visual effect.
 5. The apparatusof claim 1, wherein: the insignia includes an ink blended with lightreflecting particles.
 6. The apparatus of claim 3, wherein: theapparatus is a shirt, and the fabric is part of the shirt.
 7. Theapparatus of claim 3, wherein: the insignia includes inks printed ontothe insignia that have varying thickness that provide at least in partthe three-dimensional visual effect.
 8. The apparatus of claim 3,wherein: the insignia includes a first ink section and a second inksection, the second ink section having additive particles not present inthe first ink section, the first and second ink sections provide atleast in part the three-dimensional visual effect.
 9. An apparatus,comprising: a means for clothing; and a means for conveying a visualimage attached to the means for clothing, wherein the means forconveying a visual image includes, with respect to horizontal location,sections of ink separated by sections of flock fibre.
 10. The apparatusof claim 9, wherein: the means for conveying a visual image isadhesively attached to the means for clothing.
 11. An apparatus,comprising: a means for clothing; and a means for conveying a visualimage attached to the means for clothing, wherein the means forconveying a visual image includes stacks of ink and an insert locatedbetween the stacks of ink.
 12. The apparatus of claim 11, wherein: theinsert is at least one of foil, flock, textile, film or hologram. 13.The apparatus of claim 11, wherein: the means for conveying a visualimage includes, with respect to horizontal location, sections of inkseparated by sections of flock fibre.
 14. An apparatus, comprising: afabric; and an article adhered to the fabric, wherein the articleprovides a three-dimensional visual effect while adhered to the fabric,the article includes at least one ink layer, which provides at least inpart the three-dimensional visual effect, the article is at least one ofa decorative patch or badge, the fabric, when laid flat, has a firstsurface that is flat and one or more second surface(s) that parallel thefirst surface, the first surface being on a side of the fabric away fromthe article, and the second surface(s) being on a same side of thefabric as the article, and the second surface(s) correspond to at leastan area that is eclipsed by the article when the apparatus is viewedfrom an article side of the apparatus looking towards the fabric. 15.The apparatus of claim 14, wherein: in a state where the fabric is laidflat, a majority of the ink layer(s) of the at least one ink layer arein a same plane and parallel to one another; and the article includesink blended with additives that give varying heights to the article. 16.The apparatus of claim 14, wherein: in a state where the fabric is laidflat, surface(s) establishing a face of the article facing away from thefabric extend(s) in one or more planes, wherein if there is more thanone plane, the planes all extend parallel to one another; and thearticle includes a PU ink raised in a screen-printed pattern to provideat least in part the three-dimensional visual effect.
 17. The apparatusof claim 14, wherein: a majority of the ink layer(s) of the at least oneink layer are parallel to respective surface(s) of the fabric below theink layer(s), the respective surface(s) of the fabric being on a side ofthe fabric opposite the article; and the article includes, when viewedlooking at the article so that the ink of the ink layer(s) can be seen,a first ink containing section and a second ink containing sectiondiscrete from the first section, the second section having additiveparticles not present in the first section, the first and secondsections provide at least in part the three-dimensional visual effect.18. The apparatus of claim 14, wherein: the article includes inksprinted onto the article that have varying thickness that provide atleast in part the three-dimensional visual effect; and the article is anappliqué adhesively adhered to the fabric, the appliqué including atleast four layers stacked one on top of the other, the adhesive beingone of the at least four layers.
 19. The apparatus of claim 1, wherein:the insignia is an appliqué adhesively adhered to the fabric, theappliqué including at least four layers stacked one on top of the other,the adhesive being one of the at least four layers.